Method of making inflatable game balls



July 27, 1943. M. B. REACH METHOD OF MAKING INFLATABLE GAME BALLS 4 Sheets-Sheet. 1

Filed April 14, 1941 July 27, 1943. M. B. REACH 2,325,075

METHOD OF MAKING INFLATABLE GAME BALLS Filed April 14, 1941 4 Sheets-Sheet 2 (1H0; nous July 27; 1943. I M, B REACH 2,325,075

METHOD OF MAKING INFLATABLE GAME BALLS Filed April 14, 1941 4 Sheets-Sheet 3 July 27, 1943.

M. B. REACH 2,325,075

METHOD OF MAKING INFLATABLE GAME BALLS Filed April 14, 1941 4 Sheets-Sheet 4 WWMMWKW Patented July 27, 1943 UNITED STATES PATENT OFFICE METHOD OF MAKING INFLATABLE GAME I :BALLS Milton B. Roach, Springfield, Mass. Application April 14, 1941, Serial No. 388,533

3 Claims. (01. 15416) I cutting out of a portion of the wall of th ball The invention relates to the general form of inflatable game ball, disclosed in Letters Patent of the United States granted to me May 3, 1938,

No. 2,116,479, which is devoid of sewed seams in either its carcass or cover and embodies the char acteristic that the carcass is form shaped and is determinative of the size, shape, and strength of the ball. The present invention, however,

more specificallyconoerns the method of making a spherical ball for playing the game of basket ball, soccer or volley ball. The carcass is made mainly of substantially non-stretchable cord winding substantially in great circles.

Among objectives of the invention are perfecinvolving the cord winding can be carried on V with facility and enable thecut out portion of the wall. to; be repaired by using aspatches the material including the mesh of cord winding which was cut out to form the opening.

Preparation for allowing this cutting to be done involves the use of material merged into the car-, cass wall which material will tie or bind the cut end portions ofthe} cord windings of the patching members together so that these out out portions of the wall will be maintainedin the shape of the opening andv when restored to position 7 7 within the opening will unite with the edge porof considerable diameter as is required in building a basketball carcass thereon.

ceeded in making this. opening through the cord windings in a practical and economical manner have been enabled to repair the perforated to quickly restore the carcass wall to sub.- stantially the same shape, thickness, strength, reaction and rebound as exists in the main part of the wall of the carcass.

In making the repair of the out out portion of wal 1 preferably employ as patches cut out portions of the main. wall of the carcass both respect to the cord winding and to another layer '01" layers of textile material used in building the carcass upon th rigid form.

In carrying out the invention I employ cotton hard as the mainpart of the textile content tions of the main wallisurrounding the opening.

, It Will be understood alsothat binding or tying means have been provided for uniting together the cut end portions of the cord windings of the main "wall portion of the carcass surrounding the said opening; C

In closing the opening inthe carcass as above mentionedthe patches of cord windings which are employed are of different diameters, to fit into. the openings of different diameters in the carcass. By this'construction the patches fit upon shouldered marginsof the main wall of the car- 7 portion .of the wall of the ball built according It is necessary that dead weight (1. e. mate- I M g the ball in. order that as much cord windpossible, be used in building the carcass in the presc-ribedlimitsof siZeand weight.

is made within the carcass wall whereby the rial not contributing to strength) be avoided in.

In the cutting of the opening through the cord cass upon which the marginal portions of said patchesbear andare secured by cement, no sewing being employed at'any part of the carcass structure.

The present application is a continuationin part of my copending application Ser. No. 346,207, filed July 13, 1940,a1so my application Ser. No. 260,203, filed March 6;, 1939, and of my application Ser. No. 277,542 filed June 5, 1939, now Patent 2,255,749.0f Sept. 16, 1941. Also of cases Ser.

No. 128,672, March 2, 1937, now Patent 2,175,128 of October 3, 1939, and 144,938, May 26, 1937, and 324,215, March 15, 1940.

In the accompanyingdrawings: Figure 1 is a diagrammatic sectional view of a to my invention. V I

Fig. 1a shows a further step in thefmethod. Fig. 2 is a view similar tothat of Fig. 1 of a small portion of the wallwith a cover applied thereto.

Fig. 3 is a, face view of a portion of the ball.

Fig. 4 is asectional view similar to Fig. 1 of another form of the invention.

Figs. 4a and 4b are modifications.

Fig. 5 is a face view of part of Fig. 4 i; e with the outermostlayer of cord winding omitted.

Fig. 5 is a perspective view of a portion of the carcass partly formed and with one of the patch flaps turned back, the balloon cloth being omitted.

Fig. 7 is a diagrammatic sectional view of a modified way of forming an opening through the carcass for the removal of the material of the wax form and the insertion of the bladder.

Fig. 8 shows a further step in the method according to Fig. '7.

Fig. 9 is a diagrammatic sectionalview of a portion of the wall of the ball built according to the method of Figs. 7 and 8.

Fig. 10 is a diagrammatic view in cross section of a step in the making of another modification.

(Fig. 11 is a diagrammatic view of a further the inner edge of the main part of the cut cord winding to bind together the ends of the cord where the cut took place. A plate of metal or other suitable material 6 is now placed on the cord winding in registry substantially with the area isolated by the cut 5, but extending outwardly beyond the cut so as to overlie the main body of the cord winding, and reaching for this purpose substantially to the point I. A second layer of cord 8 is wound on the first layer 4 in great circles, and also over the metal plate 6. This second winding of textile material is laid in or with cement so that it will unite with the a first layer to form in effect one body wall which step in the making of the same modification to which Fig. 10 relates.

Fig. 12 is a diagrammatic view in cross section of a step in making a further modification.

Figs. 13, 14, and 15 are diagrammatic views of further steps in the making of this further modification.

Referring to Figs. 1 to 6:

In carrying out my invention arigid form is employed. This may be in the form of a hollow member indicated at I made of wax or other material capable of reduction, for instance by melting or by shattering the material into small bits that are capable of removal through a comparatively small opening in the carcass which is built on the said form.

Onthis form a layer of textile material 2 is applied. This may bea tubular knit fabric, say of cotton or like material, though I do not limit myself either to the form or material of this member. The tubular fabric is stressed onto the form and is stretched in so doing both in the direction of its wales and the direction of its courses, and thereafter it may be further stretched to the desired degree in any suitable manner, twisting the ends of the tubular member. In applying this first layer of the carcass wall cement is employed. This may be used to coat the wax form, or it may be applied to the tubular knit fabric either before or after said fabric is drawn onto the wax form. Excess knit material at the ends of the tubular knit fabric may now be cut away, and in each opening left thereby a patch 3 will be applied which may consist of balloon cloth which is practically non-stretchable. This patch may be covered or impregnated with cement, which will'fix said patch to the edge of the opening in this tubular knit fabric and to a layer of textile material next applied shown at 4. This last mentioned layer is in the form of cord which is wound on the foundation layer in great circles until the entire surface covered. This cord will be united with the foundation layer 2 of stock-- inette or other material by the cement with which the said foundation layer is impregnated, or by roson of the cement applied in any other suitable way, e d it will unite also with the patch 3 by the cement which is suitably ap The next step in the method of making is to cut through the cord winding and the balloon cloth patch as indicated at 5 down to the wax form. This step is performed after the cement has dried sufficiently so that the severance produced by the cut will remain effeciivefor the subsequent removal. displacement or manipulation of the cut out portions. The out at 5 is made a short distance, preferably from the of the balloon cloth patch 3, leaving a narrow portion or strip 5a underlying with the metal plate is cut through at 9, Fig. 1,

slightly within the margin of the plate 6, but out of registry with the cut 5 through the previous cord winding and to the outside of said out so 7 that the cut out section 9-9 will be of greater diameter than the previous cut out section 55 and will overlap the margin of the foundation cord layer 4, where the latter is cut out at 5. The space appearing at .c in Fig. 1a is that left in the layer of cord winding 8 by the removal of the cut out portion thereof, but it will be understood that after this cut out portion is removed so that the plate 6 can be removed, said out out portion maybe replaced temporarily to free space a: to receive plate 6 above it for cutting out the next layer of cord winding after this is applied. Therefore, after the cut out is made at 9-9 the section thereby formed is removed and the plate 6 is then removed and then the same or preferably a larger plate is placed outside this second layer of cord winding 8 but in registration as before with the cut out sections. Next a third winding I0 Fig. la of cord now can he laid in or with cement on the second layer of cord winding and over the plate. Next cut through this third winding at Hla sli htly within the margin of the plate, but out of reg istry and outwardly distant slightly from the cut 9 through the second cord winding layer so that the margin of this cut out section of the third layer will overlap the margin of the second layer at the opening formed by said out out at 9-9. Thisthird cut out section (of third layer) can be removed and the plate then can be removed.

These sections which are cut out and removed are subsequently to be employed as patches to rebuild the wall at the cutout portion thereof.

\Vhen they have been removed the wax form reduced either by melting or by shattering the same into portions or particles small enough to be readily discharged through the opening through the carcass wall which is produced as above described.

After the material of the form has been reduced and removed as just mentioned, a bladder a of substantially ordinary form is inserted into the non-stretchable carcass formed as above described, said bladder having any suitable filling valve, and then the bladder is blown up to bear against the inner side of the non-stretchable carcass.

The stem of the self closing filling valve may extend through any suitable opening in the carcasswall, or through an opening formed in the cut out portion above described.

Next the patches formed by the several cut out actions above described are replaced into their respective positions and fixed by cement. A

dipping.

strong union is formed by the restored sections or patches which overlie and, are cemented'to the margin of the main body of the layers at the opening. The inner patch of balloon cloth can be cemented to the inflated bladder, also at its edge to the edge of the main body of the first layer with which it is in line and it is cemented also to replaced sections or patches of cord winding.

The metal plate may be substituted for by any other form of divisional means that will serve as a guide in cutting the patch to restrict or confine the cutting operationto the particular lamination to which said operation is directed.

By the use of a single thin plate in the carcass at a time, for each of the cutting operations (which use virtually involves the shifting of the plate from layer to layer), the thickness of the composite patch will substantially approximate the thickness of the main body of the carcass.

wall, and will avoid the building up of extra material in the layers where the patch occurs, one object being to provide a composite patch within an opening in the main part of the composite body wall which will be substantially of equal thickness, strength, and reaction to these char acteristics of the said main wall. It will be noted that in the sequence of patching operations the ball preferably may be taken out of the winding machine after each operation.

and during this period between the'windings the rubber impregnation is obtained preferably by Each individual layer of winding is completely dried before theball re-enters the winding machine for the succeeding operation.

It is during this interval also that the patch is formed, and preferably after the winding has dried.

An advantage is obtained by applying the necessary rubber content to each layerof winding as described, as an ordinary dipping operation is sufiicient to enter interstices and coat the winding thread with the protective coating of rubber necessary to prevent cutting of the thread through. abrasion that might otherwise take place in the ordinary flexing of the walls of the ball that ocours, in play. I i

It is felt that some advantage may obtain in applying successive coats of rubber content to each layer of winding thread as formed to insure convenient control of weight contentuniform penetration of interstices and added ease of handling in the patching operations. 01 course in the final curing operation these interim layers unite and become an integral wall of cord fabrication.

The anvil plate, upon which the cutting is done, may be circular form or of other shape. It

.tions of textile'material and the cement when set is substantially non-stretchable, it is determinative of the size and shape of the ball.

' if thewinding took place upon a yielding backmay be of sufficient extent or diameter to afford a support for the cutting out of the largest section, which it will be observed is the section cut at any one time prior to performing the cutting I out of the patch. The plate maybe used as a guide to do the cutting, or, as before mentioned, as an anvil member.

These cut out secthsnsthough made of short strands of cord are collectively united by a suitable binding means that permits their handling as one body. V '7 7 Because the carcass composed of the laminareactions not uniform at ing. It is of advantage also to apply the first textile layer in the form of" a textile fabric because the cord winding willhave a suitablesurface with which to contact, and thereby to insure its retention in the position in which it is laid. This is true of the prefabricated layer or knitted fabric which has been stretched on the form before the winding of the cord thereon takes place. v I

The first cord winding will afford a proper foundation upon which the next cordwinding is Y a distended to the limit determined by building it up on the rigid form, and this distention isdue to blowingup the bladder which it now contains. These pieces of leather may be simply laid on the carcass with th ir edges adjacent, but not necessarily abutting so that channels will be left between the said edges which may be leftopen. The

sections of the'cover are cemented to the carcass.

The are not sewed together because they are not relied on to exercise "restraint on the carcass against further distention, the limit for this be ing determined, as hereinbeiore stated, by the non-stretchable character of the carcass. The carcass is flexible. No sewing is done either in thecarcass nor in thecoVer, and hence the ball, is'free from variables which sewing produces. H

The invention may be carried'o'ut in producing a spherical ball such as a basket ball, or for other purposes. When used to produce an ellipsoidal ball the cordwinding, of course, would not be laid on in great circles, but the turns would be laid on side by side. f f

By employing a hollow form. whose material is reducible as by. melting or by shattering it into hits the opening in the wall of the carcass v may of min size andthema n part of t. e Wall which is .inperforate may of maxinu n ten a d by 1 a of the s 1e main'wa and flush with the surface of said wall, wall a whole \villpresent unifo: ,f'thi ,hout ail-avoid the occurrence of vari ables.

.1 points in its contact with th oor or ct e surfaces.

The o in the car may any desired point ir tea d oi the open end of tubular f ch would produce on where t .ay occur.- Thatis to say, the opening may be made through the body of the wallet the carcass at any point thereof.

The patch of balloon cloth ties the strands.

of the adjacent cord windings together. The same is true of the knit fabric. Before applying the cover, the ball is subjected to suitable heat and pressure to eifect uniting the parts.

For convenience of illustration, the actual proportions of the parts, as well as the relative proportions thereof, have not been embodied in the drawings, so that no limitation is imposed on the scope of the claims in this regard. For instance, the anvil plate in actual practice is much thinner than shown in the drawings, and the size or diameter of the opening filled by the patch may be relatively smaller than shown.

In the foregoing description, I have disclosed patches which are completely out out, but in Figs. 4, 5, and 6, I disclose patches which remain attached to their respective main portions of the layers at one point, so that they can be turned back about this connection after the fashion of a hinge. The innermost patch 3a, Fig. 4, can be made up of a portion of the first lamination 2a of tubular knit fabric, a part of a small layer of balloon cloth 3b, and a portion 30 of the first layer of cord winding, which layer is indicated at 4a. This composite patch member is cut out in substantially rectangular form, as indicated in dotted lines 3st, Fig. 5, so as to turn about a portion 31/ serving as a hinge. Next, a disc of thin non-stretchable balloon cloth (lb of limited area is laid on the cord winding layer 4a in registration with the innermost patch 3a, and a layer of cord winding Baa is laid by a'winding machine over the layer 4a, and over the balloon cloth disc 82), and this layer of cord winding, together with the balloon cloth 8b, is cut through at 80 throughout the major portion of a circle, leaving an intact hinge,

portion at 8d, so that the flap thus formed or the balloon cloth and the superposed cord winding can be turned back leftward in Fig. 4

for the removal of the wax form and the insertion of the bladder. The direction of turning of this patch in flap form is opposite to the direction in which the composite fiap or patch at is turned for uncovering the opening through which the material of the form and the deflate-obladder are passed. The result of making the cut at 80 through the cord winding layer 8a and the balloon cloth disc to which it is cemented is to leave a narrow marginal portion of his balloon cloth at 86 as a binding for the edge of the main body layer of cord winding, it being understood that the cut ends of the cord forming the mesh of this layer are not only cemented together where they cross each other, but are also cemented to the marginal strip ilc which, therefore, acts as a binding for margin of the cut cord mesh.

The mesh of crossing thread formed by winding in great circles is indicated in Figs. 3, and 6. This is representative of each individual layer of. cord winding. This mesh being made up of the cord crossing itself, as a result of winding it in great circles, and cementing of the portions of the cord together at the crossing points, is self-contained in the sense that it will constitute a flap or patch even though the disc of balloon cloth or other fabric is not present.

For convenience of illustration, I have not attempted to show in the sectional views, Figs. 1 and la, that each of the layers 4, 8, I0, and

in Fig. 4, that each of the cord winding layers 4a, 8a, and Illa, is made up of the cord crossing itself when wound in great circles, but it seems suflicient for those skilled in the art to mention the fact that each lamination of cord winding is of this construction i. e., laid on in great circles with the cord crossing itself many times, as indicated in Fig. 3; also in Figs. 5 and 6. I have also indicated in Fig. 6 that fabric such as balloon cloth may be omitted reliance being had upon the crossing of the cord of each layer to provide the self-contained textile mesh thereof whether in the main body, or in one or more of the flaps or patches.

A third layer of cord winding may be applied to the ball in great circles and with the cord crossing itself many times, like that shown at 8a in Fig. 5, it being understood that for convenience and clarity, this third layer is omitted in Fig. 5.

This third layer is indicated diagrammatically in Fig. 4, at 10c. no attempt being made in this cross sectional illustration. to show the crossing of the cord in the winding by great circl Before applying this third layer of cord winding, a member iflb of re-fabricated textile material, such as fiin balloon cloth, is applied outside t. e winding 8a and in registration with the patched area, and this layer, which, like the other layers of balloon cloth, is non-stretchable, cut through, together with the third layer of cord winding, at ltc. but is left intact at one point to form a hinge allowing this pat-c member to be turned back inorder to expose the opening for the removal of the reduced material of the wax or other form, and for the insertion of the bladder. The hinge or intact connection between this flap or patch member is located at a different angular position about the opening from where the intact or hinge portions or": the other patches are located, in Letters Patent of the United States No. 2,116,479, dated May 3, 1923.

g The patches or flaps increase in diameter in respect to each other, the inner one being the smallest, and the outer one being the largest, so that each patch, excepting the inermost, at its margin will overlie the marginal portion of the main body layer next below it.

In forming the patches or flaps of Fig 4 and 5, the process described in connection with Figs. 1, 2, and 3 is carried out so far as the use of the plate 6 is concerned, which is employed as an anvil for doing the cutting thereupon, or as 0. guide or pattern for making the patch, said plate being shifted from layer to layer as the work of building up the patched area progresses. Ey the use of the non-stretchable fabric and the cord windings which are laid tightly in place, patched area is substantially non-extol. id this is substantially true also of the main oody of the carcass made up of the tightly applic winding impregnated with cement, and ce1..-ented one layer to another.

The bladder may be cemented directly to the inner layer of textile fabric and the cover directly to the cord winding, and the latter laminations may constitute the entire carcass structure between the bladder and the cover except for the inner layer of pie-fabricated textile material. I

Where a feature of one form of the invention may be embodied in the organization of another form, it is to be considered as existing therein.

It'will be seen that the laminations oi cord winding provide a ball which when cemented .together ready for use presentsa substantiallyhomogeneous carcass portion including the mesh sections constituting the patches.

The use of the layer or patch of balloon cloth over which the cord winding is applied and co; mented thereto acts as a reinforcing means at the area where the cutting out action is ,pere formed through the card, it being observed. that the cutting is continued through this layer and necessarily in registration with the cut through the cord winding. It is a reinforce in the sense that it holds the strands of cord cemented thereto in proper position for the cut to bejmade conveniently, and when made, it holds the cut ends in their initial relation to each other, thus avoiding the occurrence of loose cut ends, liable to become misplaced. All of this is true also of the cut ends of the cord windings at the edge of the main body of the carcass defining'the opening left by the cutting out of the patch from the mainbody. vIn other words, when the cutting is completed through both the .cord winding lamination, or laminations, andthe layer or balloon cloth or other material, there will be pro vided a binding for each of the opposing margins along opposrte sides of the cut through. thecord windings, each binding holding together the cut end portions of the cord on its side of the out.

These bindings of balloon cloth along eachmar;

gin of the cut areunited by cementing them together and/or to the adjacent lamination of the carcass. I do not limit myself in this respect; I prefer to cement to the exterior lamination of cord winding in great oirclesas described, .a sub-surfacing layer of relatively close mesh prw fabricated material similar to balloon cloth or fine sheeting material, which will compensate for any slight irregularities arising from the winding operation. This is indicated in Fig. 4 at 3d. Upon this sub-surfacing lamination, the cover panels of leather or like material are cemented.

I do not limit myself to the shape of the cut made through the cord winding inorder to .provide for the removal or thereduced rigidforrn and the insertion of the bladder, but it is or inipo ace in closing this opening to restore the carcass wall at this point, that the margin of the out be reiniorced by a'layer of material, for instance, balloon cloth, to act as a-bindingalong margin to which binding memberlthe cut ends of the cord windings remain cemented. Neither do I limit myself to any particular way of afiixing themargins along the cut in place.

I have before stated that the use of the. first layer of textile fabric applied to the form provides a suitable surface for receiving and holding against displacement the winding of textile ma-j terial applied'thereto. The surface thus afford} ed is of a friction character on which the winding will not slip. I do not limit myself vto .the particular material, i. e, knit fabric, as other 4a, may be applied on the layer I00. and over its patch 100-400, and this outer layer isnot cut through, but is intact throughout so that it acts as a reinforce for the patches against gas pressure within the carcass. This construction is illustrated diagrammatically in 4a, the layers for convenience being shown as flat instead of curved, and only the layers constituting the cover H, the subsurfacing layer 3d of balloon cloth, the reinforcing or uncut cord Wind ing l0ar,'the cord winding llla, and the patching disc or layer of balloon cloth lib being shown, the other layers shown in Fig. 4 being omitted for convenience of illustration.

The subsurfacing layer 3d as shown in Fig.

42) may have a layer of moldable material as rubber between itself and the cover IL. This moldable material is shown at H3. The subsurfacing layer serves to close the interstices of the cord winding layer underlying it and insures that the moldable material will flow as intended, when heat and pressure of the mold is applied in finishing the ball. The moldable material will extrude into spaces betweenthe sections or piece s of the cover ii. This will form a rib I? which is grooved'for flight direction and for a finger hold. I

The drawings Fig. 4b for convenience show only the three layers of material mentioned above i. e. the cover, the moldable material as rubber, the subsurfacing layer and the uncut layer I611: of cord winding, but it will be understood that other inner layers making up the carcass are used in practice, but are omitted here for il because the channel seam per se is claimed in my Patent No. 2,182,052, Dec. 5, 1939.

In the foregoing description the cord winding" is applied in stages and in separate lengths of cord, one length for each stage. This is for convenience in applying the vulcanizable cement stages by dipping the carcass in a bath and without the useoi pressure, it being understood that under normal atmospheric pressure the cement will readily permeate the comparatively thin lay ers of cord winding, made up of only the turns of said cord, derived from each length. Because at thebeginning of each winding operation the end of the newlength of cord is held by any suitable sticker or inany other way to the previous- .1 applied textile layer, whether this be cord winding or the tubular knit fabric hereinbefore material may be used for this first layenhaving.

the desired surface to which the textile winding may be applied without slipping, despite the def gree of tightness with which the winding is applied.

The subsurfacing prefabricatedmateri'al of balloon cloth 3d or sheeting maybe applied in segments cemented edgeto edge upon the outer layer Illa of cord winding.

This outer layer of cord winding may be that part, or another layer of cord winding lilr, Fig.

referred to, the entire winding virtually constitutes in effect one continuous cord orwrapping.

. Instead, however, of using lengths of cord by dividing the entire yardage up into separate pieces, the cord Winding may consist of only. one length or piece of cord and Figs. 7, .8 and 9 may be considered as embodying but one length of cord. This single strand or length is applied with certain interruptions but without severing the cord into separate lengths, the interruptions in the winding action providing the intervals of time during which the cementing material for the patches is applied.

' Referring to Fig. '7 a portion of a hollow spherical wax form is indicated at i, tubular knit fabric or stockinet is shown at 2. The patch of balloon cloth hereinbeiore clescribed in connection with Figs. 1 to 6 inserted in the open end or" the over the anvilfplateor guide is 'laidfa patch.

a plurality. of

member 8 of balloon cloth, the diameter of which is larger than that of the metal anvil plate 82) and the first patching member 3. Next the cord winding 6b is laid on the stcclzinet (it being shown for convenience spaced apart) substantially in great circles, as before described in connection with Figs. 3, 5 and 6, and after the desired number of turns of cord are laid the winding operation is arrested but without break: ing the cord, whereupon a second metal anvil plate 60 of larger diameter than the fi st anvil plate 62) is laid on the cord winding and a third patching member 8g is lai: on the anvil plate 6c and of larger diameter than said plate 6c and of course larger in diameter also then the patching member 8f. The winding of the cord in great circles is now resumed and is continued until the desired thickness of this main part of the carcass is attained the turns of the cord crossing the turns previously laid and making a wall of substantially uniform thickness and uniform fabrlcation because the mesh having been derived from a winding machine of the eneral type ployed in winding the body of base balls will have its interstices of substantially uniform size and disposition so that the vulcanizable cement with which the wall of cotton cord is impregnated will be substantially equally distributed with a view to producing an accurately shaped and balanced ball. After the winding is completed preferably with one length or strand of cord for the entire yardage desired the ball is taken from the Winding machine and placed in a bath of the micanizable rubber cement until the desired amount of cement has permeated the textile body, suitable'pressure being applied if desired to cause the liquid cement to permeate the to the desired degree. After removal from the bath and allowed to dry the carcass is cut to provide an opening therethrou gh at the patched area of Fig. 7 for the removal of the material of the wax form when the latter is reduced to fragments by breaking it up or by melting it. a

Fig. 8 shows the opening at AAA in the carcass and also the patches which result from cutting out portions of the carcass. The cutting is not done until the carcass with its patched has been built up into the form shown in Fig. 7 with the anvil plates and balloon cloth members 3, 8] and By in place. The first cutting action takes place through that portion 'of the cord winding that lies outside of the patch member By, the cut being continued through said layer 89 of the patch material down to the anvil plate 60. This cut is represented at me. It may be located either at or slightly within the edge of the said plate and the drawings Fig. 7. show it in the latter situation, i. e. inward of the patch and slightly spaced apart from the edge thereof.

This patch with quota of cord winding comented thereto is shown in Fig. 8 separated from the carcass structureindicating that the patch may be entirely severed from the carcass, but it will be understood that if desired it might be in the form of a tab as previously dt'lSClibCd remaining attached at one point to the main body of the carcass, as shown in Fig. 6 at ca and 3x. In Fig. 8 the cord winding at the outer surface of the carcass is shown in a plurality of turns, this being representative of any desired number of gs to build. up the carcass of es and weight of the nonstretchable cotton cord. 7

I Outside of the cut lfld Fig. '7 it will be seen that a band or ring shaped portion 8h of the balloon cloth patching material is left cemented to the overlying main body of cord winding. This ring binds together the end portions of the cut cord of the main wall of the carcass along the margin of the cut ma and likewise the patch 89 of balloon cloth in connection with the vulcanizable rubber cement will bind together the strands of cord winding left on said cloth by the cut lid. The turns of cord where they contact each other at their points of crossing will be cemented together.

The cut Hid instead of being made upon the plateic within and slightly spaced from the edge thereof may be made across said edge.

After this outer patch has been out, the plate 60 is removed and the second patch U is cut out using the metal plate 61) as a guide or as an anvil plate. This cut will take place through the cord winding which covers the patch material Bi and as the anvil plate 6b is smaller in diameter than the anvil plate 60 and is used as a guide or anvil for doing the cutting the patch 8f will be smaller in diameter or area than the patch 8g and this relation is shown in Fig. 8 where this patch 8! is shown separated from the main body of the carcass.

Fig. 7 does not show any out through the patch material 8) because the cutting of this material can not be made until patch 8g and plate 6c are removed.

As a. result of the operations just described patches 8g, 8] and 3 are provided having the same make up as the main portions of the carcass from which they were cut, and it follows that if these patch members are restored into the opening in the carcass and securely vulcanized in place, the patched part of the carcass will be of substantially equal strength with the main part of the carcass and will have like reaction and rebound. Contributing to the effectiveness of the patching above described is the use of the cord winding as a part of the patches provided by cutting said patches from the cord windings in great circles forming the main wall of the carcass of the ball, and the use of the thin light weight reinforcements of balloon cloth to which the cut ends of the cord are cemented and which tie the said out ends together both along the margin of the opening in the main part of the carcass and also along the margin of the patch itself. Where a patch member is cemented to a surface or shoulder on its underside as indicated in Figs. '7, 8, and 9, the union is of much greater strength than if the union consisted only in ceine'nting together the abutting edges of the patch and the layer of the main wall of the carcass. Further contributing factors are the replacement of the patches in the openings in the carcass formed by cutting the patches therefrom.

.This patch 8! carries cemented thereto the cord winding which was cut out during the same act of cutting out the patch itself. There will be a band or circular strip 82', Fig. 8 of balloon cloth left connected with the main wall portion of the carcass, having cord winding cemented thereto and the patch 8 f will carry its. own quota of cord winding.

It will be understood that after the patching material has. been cut to form the patch 8 and the ring shaped reinforce 81, using said plate 612 as an anvil, the patch 8f together with said plate 6b are removed and the cutting then can be continued through the inner layer of patch material to provide the main part 3 of said inner patch andits ring portion se, the latter remainpart of the carcass.

ing as a part of 'th'e main carcass portion ofthe ball.

The ring 8i will lie on the stockinet layer and in part on the marginal portion or ring '31; of the inner patch material 3 left by cutting out the center portion of the said patch material which initially filled the open end of the tubular knit fabric.

In carrying out the cutting operation the cut made through the patch member 3 maybe continued through the wall of the hollow wax form I as indicated at B, Fig. 8, so that the wax may be reduced by using a steam nozzle inserted through said opening, but I prefer to break up the form into such small fragments that they can be readily removed through the openingin the carcass, and indeed can be poured out through said opening.

After the wax form is reduced and the material thereof is removed the patching or restoring of the carcass can be done for which purpose a foundation member is positioned within the carcass. This may consist of an inflatable bladder a as in Fig. 9 or any other suitable member may be employed which will afford a support upon which the inner balloon cloth patch 3 is laid. The bladder is inflated (by any known self clos ing valve) so as to close the inner end of the opening through the carcass whereupon the patch 3 is cemented in position as shown in Fig. 9

with its edge abutting the ring 36 which originally as shown in Fig. 6 initially had been an integral part of said patching material as'in' Fig. '7 when first built. Instead of using the inilated bladder as the foundation member on a which to build the patch element of Fig. 8 with the restored or patched part of the carcass wall, I may employ a strip of material. attached at the margin of the opening in the carcass and within the same as at 5a Fig. 8 of Letters Patent of the United States granted tome May 3, 1938,

No. 2,116,479. p

, After the patch 3 is cemented in place within the ringer strip 36, the patch 8 whether in the form of a disc or piece entirely separate from the carcass ring or strip 82' or hinged thereto in the carcass member or balloon cloth strip 3e.

ihis patch member 3] abuts edgewise against the inner edge of the carcass stripBi to which it is cemented; The cord winding onthe patch 8f" is cemented to the cord winding of the main mented in place within the strip or balloon cloth ring 8b of the carcass with which it registers and it finds a supporting shoulder below it on the upper or outer surface of the binding strip 82' for the edge of the carcass around the opening therein shown in Fig. ,8 and designated generally by the letter A. This opening istapered from the outer side of tie carcass inwardly towards the center thereof and th composite patching means is of corresponding shape by reason of the shouldered formation resulting from the difference, in the diameters of the patching members or layers of material making up the patched area.

The composite patch is flush with the carcass at both the outer and inner sides thereof.

The inwardly tapered form offthe patch made The patch this next ,ce-'

up of the cord windings and the balloon cloth provides a strong repair structure to resist blows upon it during play and this is so despite the fact that the composite patched area is made up in part of turns of cord winding. Contributingto this i the fact that the cord winding of the patch is cemented to binding material such as balloon cloth.

The sub-surfacing layer of balloon cloth may be applied on the outer side of the cord winding layer as in FigsAa and 41) so that in this respect the form shown in Figs. 7, 8 and 9 would belike Figs. 4a and 4b. I have not attempted to show in the sectional views as l, 8 and 9 that the cord windings crosseach other, nor have I attempted winding constituting the cord constituent of the carcass.

I have thus far disclosed herein two different methodsof patching the carcass to close the opening made therein for the removal of the material of the rigid form when reduced and have preferably shown a sequence of multiple patches in strengthening the cross section of the cord wound ball. It may be assumed however that sufficient strength may be attained for all ever, that in all assemblies the principle of multiple patches'whose jointures are out of registration, one with another, thus providing a shoul der, must be employed to haverequisite strength and durability, and this is the dominant feature underlying this repair element.

l/Vith this form the entire quantity of cord winding can be applied at one operation.

Certain characteristics of the materials enternto the construction of the carcass are mentioned below, from which it appears that the winding of non-stretchable cotton cord is thef It is laid.

predominant element of thecarcass. on the rigid form in great. circles with uniform tension and contributes especially to the uniform shape of the carcass, itsunifcrin strength and reaction in rebounding. The weight of stockinet "or tubular knitted fabric before impregnation with the cement is .60 oz. and after impregnation 1.10 oz.

The weight of cord winding before impregnation is 4.00 oz. and after impregnation 4.91 oz.

The thickness of the. layer of cord winding is approximately .120 inch.v

The material used in making the cord winding is cotton %2-" staple.

The gauge of the cord is 12/2/12.

-The materials just mentioned enter into the construction ofthe carcass of the ball, and the cord winding may be said to constitute the outer member of the carcass becau e in some instances, where the so-called channel seam such as shown in Fig. 4b at H is not wanted, the leather cover may be thenext element placed in position outside the cord, this being cemented down on the cord winding of the carcass, after the winding of the cord is completed.

The winding of the cord in great circles is done by a winding machine under uniform tension and therefore is performed with accuracy so that the spherical shape of the ball is attained.

When the balloon cloth covering or sub-surfacing layer outside the cord winding is used it is employed not as a carcass member contributing to the shape of the ball, but on the contrary, its main purpose is to prevent migration of. the rubber material 16 into the carcass and there fore to insure the supplying 'of the'speci fied amount of rubber necessary to flow into and. fill the space between the sections of the cover as in The weight of the cord winding being 4.00 oz.

as compared with .60 oz. which is the Weight ofals i a i ing of a basketball and would vary asrequired the stockinet and the thickness of the cord layer being .120 inch, which is greater than the thick nessof the tubular knit fabric, said cord winding becomes the predominant element of the carcass construction and being wound on a rigid form g in great circles the turns of which cross each other many times and united by the cement at the crossing points is mainly responsible for the accuracy of the balls shape as well as its other desirable qualities.

".As to the prefabricated cloth sub-surfacing material 3d of Figs. 4a and 412, this sheeting is of 5 oz. grade and weighs before calendering .10 oz. per panel (8 panels being used) and after calendering its weight is .78 oz. per panel or 6.24 oz. per ball.

The weight of the balloon cloth contained in the'patching organization shown in Figs. '7, 8 and 9, a part of which serves to bind together the cut end portions of the cord winding atthe opening' formed in the carcass for the removal of the form is considerably less than that of the cord winding.

This balloon cloth consists of the discs and tabs and. strips or rings shown in Fig. 8. They are small in diameter as compared with the diameter of the ball and they are quite thin and while' they are non-stretchable and strong they take up. only a little room and leave a maximum space for occupancy by the cord winding upon which main reliance is had for strength.

l The Weight, of the leather cover before cementing is 4.20 oz. and after cementing is 4.56 oz.

The weight of the bladder is 3.30 oz.

The sub-surfacing member 3d when impregnated with the vulcanizable rubber adds materially to the weight of the ball but this excessive rubber content is required to produce the'channel seam of Fig, 4b.

The gauge of cotton yarn of which the tubular knitted fabric is made is No. 16840 yards to the pound.

Weight of large and small patches Small Ounces Cloth without any cement ".04 Cloth with cement. spread .05 Cloth coated .11

Large Cloth without any cement .07 Cloth with cement spread .08 Cloth coated .18

Use of three small and one large patch is presr ea I do not limit myself to the balloon cloth as the means together with bonding material for bonding together the cut end portions of thecord windings, or sections thereof, as othermeans may be used for this purpose.

The invention is notrestricted to any particular type of inflated ball and, while such types as volley balls, soccer balls, and basketballs vary considerably as to size, weights and quantities of constituent material, as well as to inflation 5 pressure, it will be understood that the invention provides a carcass which is relatively non-stretching in play under the inflation pressure normal for the type of inflatable ball being bu'iltfth'er'e beingno intent of providing carcass walls of ex: 10 ces's'str ength and, weight to 'Withs'tand'pressures materially excess of those used in actual play, the fa ctors or weight and rebound being con rol ling elements.

Theforegoing characteristics as to proportions and weights and other items, pertain to the makfor other types of inflatable balls.

' Referring to Figs. 12, 13, 14 andv 15, these show a construction similar to that of Fig. 11 involving afmain carcass layer comprising a solid mass entirely of cord wound continuously and uninterruptedy of a single strand or piece of cord and outside of. the patching means of sheet material,

but'in Figs."12 to 15 the patching means, which underliesthe main carcass portion of solid cord, comprises a plurality of layers of patches of sheet material of limited extent as seen in Fig. 15.

Fig. 12 a wax or other reducible form is indicated at 'l, and the numeral 2:1: represents the foundation layer which may be of stockinet or tubular knit fabric or may desirably be a film or layer of rubber or rubber cement providing the non-slipping surface for the cord winding as described; in my copending application Ser. No. 324,215; filed March 15, 19,40. A patch of balloon cloth or other sheet material 3g or" limited area may be inserted in the open end of the tubular knit fabric as'hereinbefore described and shown: in connection 'with' Figs. '1 to 11 or placed on top of the stockinet or rubber foundation layer, and a metal or'other plate 6e resistant to cutting may desirably be placed on top of the patch 39.

Over the plate 62 another patch 82' is applied and an opening is preferably then cut through the patch 81 and the plate removed and a sprinkling of talc or a layer of preferably glazed paper is'putunder the cut out portion to keep it from cementing itself to'the underlying patch. The same or preferably a larger plate 6f is then placed on top of the superimposed patches 3g and 82'.

Another patch 870 is preferably then applied to the metal plate 6 and over this patching structure as well as over the entire foundation layer 210 on the form there is wound the cord prefer-, r ably in'one continuous unbroken strand and in one continuous uninterrupted Winding operation forming a main carcass portion comprising a solid mass entirely of 'cord C, the cord winding being continued until a carcass wall of. sufiicient strength is provided. In the winding operation and the subsequent cementing operation the cord Winding becomes attached to the covering patch on the plate.

The views in the drawings are diagrammatic andfexpanded to enable the thin layers and patches to be seen in their relation to each other, alndactually there is no space between the cord layer. and the layer 2:12 on which the cord is After the cement has dried a cut may desirably be made through the main carcass portion of cord 0 and through the patch 8k down to the cutting plate Si and the plate removed.

The out portions are then openedup, as repre- 7 sented in Fig. 14, and a cut made in the inner patch 3g and against or through the wax form, the material of which is then removed through the openings. This cut may desirably be made smaller than the previous cut and out of registry therewith to provide a, shoulder, as shown.

As hereinbefore described, the openings may desirably have their margins in offset relation providing the shoulders with portions of the patching material binding the edges of the adjacent cut layers including the main cord layer and cemented thereto as previously described in connection with the other figures of the drawings. Also instead of being out completely out, the cut portions may be in the form of tabs or flaps hinged at one side as described in connection with Fig. 4.

After removing the material of the form, a bladder B is inserted, the cut portions are cemented back into place to close the openings, and

a final uncut patch 8m of sheet material and of restricted area is desirably placed on ,top of the cord overlying the cut therein and binding the cut margins of the cord as seen in Fig. 15. Fol lowing the application of the uncut patch 8m, or if the patch 8721 is omitted, a subsurfacing layer (not shown) is preferably applied over the entire carcass and over the patch 8m, such as described and shown in connection with Figs. 4, 4a and 4b, a rubber coated fabric as shown in Fig. 4b being a desirablev form of subsurfacing material to which the cover material of leather may be applied, as hereinbefore described,

I claim:

1. Steps in a method of making a spherical inflatable game ball consisting in applying to a rigid reducible form material providing a nonslipping surface, applying a patching means of sheet material of limited area and in one or more layers, applying upon said patching means a plate member substantially resistant to being out, said plate being of limited area, applying over said plate another layer of patching material in sheet formand of limited area, winding cord substantially in great circles onto said form and over the outside of the patching material, said winding being performed continuously and uninterruptedly and of continuous strand of cord and forming a solid mass entirely of cord constituting the main portion of the carcass of the ball, impreghating the cord winding with cement to bind it together and to the underlying layer of patching material, cutting through thesolid mass of cord winding and through the patching material down to the plate, opening the same, removing the plate, providing openings in the underlying patching means as by cutting down through the same to the form, reducing the form and removing it through the openings in the carcass, inserting means rendering the ball inflatable, and closing the opening by restoring all the cut out patching portions and the cut out portion of the overlying main wall portion of solid cord.

2. Steps in a method of making a spherical inflatable game ball consisting in applying to a rigid reducible form, material to provide a nonslipping surface, applying patch means of sheet material of limited area, winding cord in great circles onto the non-slipping surfacing material on said form and outside said patch means to cass.

form a solid mass entirely of cord constituting the main portion of the carcass wall, the winding of the cord taking place in great circles with a continuous strand and continuously and uninterruptedly and entirely to the outside of said patch means, applying cement binding the cord together and to the patch means, cutting an opening through said solid mass of cord winding and cutting through the binding patch means down to the reducible form, said cutting through said solid mass of continuous strand great circle cord being performed by cutting substantially radially straight through said solid mass of cord from the outside to the inside thereof, reducing the form and discharging the material of the reduced form through the opening in the patch means and the opening in the cord winding, inserting means rendering the ball inflatable, and

applying closure means to the openings in the patch means and in the cord winding, substantially as described.

' 3. Steps in a method of making a spherical inflatable game ball consisting in applying to a rigid reducible spherical form a layer of material having a non-slipping surface, applying a patch of sheet material of limited area, applying a plate member substantially resistant to being out upon said'patch, said plate being of limited area, ap-' plying over said plate a patch of sheet material, cutting an opening through said last mentioned patch down to the plate, removing the plate, ap-

plying isolating means under the cut portion of said patch so that said out portion will not cement itself to the patch of sheet materialunderneath, placing a second plate over the cut lamination, placing another patch of sheet material over said second plate, winding cord in great circles onto the form and over the outside of the outermost patch to form the main body of the ball carcass of'said cord, impregnating the cord winding with cement whereby the cord winding becomes attached to the said patch of sheet material on the second plate, allowing the cement to dry, cutting the cord winding and through the outermost patch of sheet material down to the saidsecond plate, removing the plate, opening all the cut portions and then cutting through the innermost patch of sheet material against the reducible form, reducing the form and removing it through the opening in the carcass, inserting means rendering the ball inflatable and closing the opening through the cord winding carcass and patch laminations by restoringsaid cut portions in cemented relationship, said cord winding forming a wall of sufficient thickness to provide the required car- MILTON B. REACH. 

